Oil & Gas, Power Generation, Process Industry

High Speed @ Power Gears

Innovative Power Transmission

Gear units – Technical Basis

Sheet 1

Our Experience makes your Application DependableThe Genuine RENK TA Gears Famous for Reliability

Ever since 1935 RENK AG have been de-voting intense efforts to the development and manufacture of high-speed gear units and as early as in 1939 bearing journal speeds of 110 m/s were attained and con-trolled to guarantee operational safety. In 2012 near to 5500 TA high-speed gear units were in service. Among these are gear units with circumferential speeds of 220 m/s and bearing journal speeds of 140 m/s. These gear units are used in almost any industry with focus on power station technology, process technology and chemical industry.

In the beginning the toothing was just “natural hard”. Since the late 1960ies RENK offers gear units with fully-hardened toothing exclusively (case-hardening). In this way the pitch line velocity has been reduced by 40%. The transmittable power has been increased by the factor of 4 with the same gear wheel dimensions. Today RENK manu-facturs high-speed gear units for power values of 140 MW. Since 1975 RENK holds the world record for the ultimate power transmitted in a gear stage.

The feasibility studies reached powers beyond 300 MW for generator drives.The essential feature of TA high-speed gear units are tailored to the relevant application, optimized center distance bearing dimen-sions and tooth width as well as standard-ized monitoring systems to satisfy maximum requirements. The target is low power loss, noise and vibration. As of the following high-speed gear unit variants our application specialist will consult you to find the best solution for your case.

High Speed Gear Unit Type TA50Xi World record in power transmission: 137 MW Gasturbine Load Gear2

In house hardening

Tooth quality 5 is standard, 4 or 3 is an option

Load pattern: 100 % under load

Tooth width up to 1,000 mm

Latest state gear cutters and grinders are producing the product core: the gear set

3

Gear units – Options

High-Speed Parallel ShaftGear Unit Series TACharacteristics and Design Variants

Gear units of series TA are of modular design allowing the best possible adaptation to the requirements of the shaft train.

TA Double-Helical toothing

Suitable for the transmission of axial thrust e.g. from couplings or electric machines. Axial bearing preferably on the low speed shaft.

➊ Gear set• Toothing case-hardened and ground.• Integrated quill shaft on demand.• Flanged shaftend on demand.

➋ Gear unit casing• Fabricated partly double-walled, for

noise-dampening.• etaX (reduces loss) technology on

demand.

➌ Radial bearingsSleeve bearing geometry:• Cylindrical 2-lobe• 4-lobe• Offset• Double offset

Further developed by RENK:• ISOPRESS (reduced loss)• EXCO (reduced temperature)• Tilting pad per bearings on demand.

➍ Axial bearingSelf-aligning tilting pad bearing in with or without separate housing or tapered land type. Depending on speed and application tapered land shoulder bearings are the technical and commercial optimum. The axial bearing layout and design is recom-mended on individual basis. Instead of a flexible coupling an integrated quill shaft can be applied usually on the bull gear shaft. This makes the shaft train shorter and allows shock torque compensation.

➎ Oil pumpDirectly driven or via geared PTO on demand.

➏ Turning deviceWith fully-automatic RENK SSS-overrun-ning clutch or with semi-automatic claw overrunning clutch on demand (ask for leaflet).

➌

➋

➌

➍➎

➊

TAD

TAE Single-Helical toothing

Suitable for the compensation of high axial thrust in combination with rigid couplings.Cost-effective variant if axial forces are absorbed by driver or driving machine. Axial bearings possible.

TAD Single-Helical toothing with Thrust CollarSuitable for the tranismission of high axial forces (compressor or turbine thrust). Axial bearing on the low-speed shaft.

➎

➏➌➌

TA ➋

➌➍

➊

➊

➋TAE➎ ➍

➌

4

Application examples

The following examples are to be understood as standard solutions.Other combinations may proofe preferable in the clarification phase:

Application Criterion Typ (ref. overleaf) Coupling (recommendation)

High-speed machine (Compressor, Turbine)Electric machine (Motor, Generator)

Small to maximum power valus, low acial forces.Axial bearing inside gear unit.

TA

Pinion side: axially flexible coupling(RAFLEX MTM, MTR, Diaphragm MCF).Gear side: axially stiff flexible coupling (RAFLEX MSL, MTP, curved tooth SBR, SRL). Flange coupling, if necessary with quill shaft (integrated).

High-speed machine (Compressor, Turbine)and Electric machine (Motor, Generator)

High and maximum power valus.Axial bearing inside high-speed machine.

TA

Pinion side: flange coupling withquill shaft (external or integrated) or axially stiff flexible coupling (RAFLEX MTM, MTR, Diaphragm MCF).Gear side: flange coupling if necessary with quill shaft (integrated).

High-speed machine (Compressor, Turbine)without axial bearing

Small to high power values.Axial bearing inside gear unit.

TAD(on compressor foundation)

Pinion side: axially stiff flexible coupling (RAFLEX MTM, MTR, Diaphragm MCF) or rigid. Gear side: flange coupling with quill shaft (external).

Electric machine (Motor, Generator)without seperate axial bearing

High-speed machine (Compressor, Turbine)

Medium to high power values and high axial thermal growth with/without axial bearing in gear unit TAE

(on high-speed machine`s foundation)

Pinion and gear side: axially stiff flexible coupling on gear side (MTL, MTK, SRLK). or Flange coupling, if necessary with quill shaft (integrated).Gear side: flange coupling with quill shaft (external).

Electric machine (Motor, Generator)

Piston, CompressorTB

(2 stages)Caution: propper axial prestress of dry couplings required.

*DBSE: Distance between shaft ends

integral quill shaft

Conventionalshaft coupling

DBSE*

5

Sheet 3

Gear Units – Technical Features

High-speed Parallel ShaftGear Units TA ..X/TB ..X/TA..XiGear Unit Casing, Noise Reduction and Instrumentation

Cast casings are specifically rigid and noise optimized.

The fabricated gear casing houses either four (TA) or six (TB) radial plain bearings in which the gear set is guided. Welded casings enable for the use at any ambient temperature.

• Double-walled design with maximum stiffness.

• Noise dampening without adverse effect on easy maintenance.

• If required the design can be adapted to customer requirements as to orientation of oil connection, shaft height center distance etc.

Optimization results in a selection of best possible bearing load, shaft bending and necessary oil expansion spaces (favorablepowerloss) as well as pitch line velocity.

The oil distribution to each consumer(4/6 radial bearings, ½ axial bearings,turn drive) features oil quantitiesindividually adjustable by orificies,accessible without unit disassembly.

Welded casings are partly double walled for best noise dampening.

TAxi gear units have been specially designed to provide versatile instrument features such as:

• Temperature Probes (any quantity)• Shaft vibration probes (up to 8)• Phase angle/speed detectors (up to 4)• Acceleration/velocity probes (any no.)

The specific feature the complete wiring on the lower casing.Fittings are from stainless steel, cables are run in heavy duty flexible conduit.

6

The heariest bull gear for the world most powerfull compressor

drive built by RENK transmits 108 MW at a weight of 6,900 kg

The production of 100 MW load gears exceeds 130 units in 2012

More than 5,500 RENK high speed gears have been supplied

TA71 Gear unit being assembled

7

Gear units – Technical Basis

High-Speed Parallel ShaftGear Unit TA ..XiYour application – our attention

50.0

40.0

30.0

20.0

10.0

9.0

8.0

7.0

6.0

5.0

4.0

3.0

2.0

1.0

0.9

0.8

0.7

0.6

0.5

0.4

0.3

1.21 1.3 2

Gear Ratio : i = High SpeedLow Speed

3 4 5 6 7 8 9 10

=

Rate

d P

ow

er

Lo

w S

peed

p nkW

TA 100X

TA 90X

TA 80X

TA 71X

TA 63X

TA 56X

TA 50X

TA 45X

TA 40X

TA 36X

TA 32X

TA 28X

TA 25X

rpm

Shaft assembly R-L Shaft assembly L-R

Shaft arrangements:

Size (A) Gear (ratio) M1 [mm] M2 [mm]

TA 20X i 1.2 - 3.2 340 340

200 3.3 - 5.2 330 330

TA 25X i 1.2 - 3.0 450 450

3.1 - 5.0 380 390

250 5.1 - 7.0 320 320

TA 32X i 1.2 - 3.0 515 515

3.1 - 6.0 450 450

320 6.1 - 9.0 340 340

TA 36X i 1.2 - 3.0 550 550

3.1 - 6.0 460 460

360 6.1 - 9.0 370 380

TA 40X i 1.2 - 3.0 585 590

3.1 - 6.0 510 510

400 6.1 - 9.0 375 410

TA 45X i 1.2 - 3.0 635 640

3.1 - 6.0 550 550

450 6.1 - 9.0 420 430

TA 50X 1.2 - 3.0 700 705

3.1 - 6.0 570 575

500 6.1 - 9.0 460 480

TA 56X i 1.2 - 3.0 760 765

3.1 - 6.0 610 620

560 6.1 - 9.0 490 500

TA 63X i 1.2 - 3.0 810 820

3.1 - 6.0 645 650

630 6.1 - 9.0 540 550

TA 71X i 1.2 - 3.0 820 840

3.1 - 6.0 675 680

710 6.1 - 9.0 565 580

TA 80X i 1.2 - 3.0 860 860

3.1 - 6.0 720 730

800 6.1 - 9.0 630 650

TA 90X i 1.2 - 3.0 920 920

3.1 - 6.0 785 800

900 6.1 - 9.0 650 660

TA 100X i 1.2 - 3.0 920 920

3.1 - 6.0 830 840

1000 6.1 - 9.0 700 710

8

Shaft arrangements:The gear-unit with double-helical toothing (axial tooth force compen sation), with or without axial guide on the low-speed gear shaft.

TAE Single-helical toothingThe classical gear unit with single-helical toothing and free axial tooth forces which have to be absorbed by thrust bearings at the input and output shafts. The trust bearings cabn be arranged in the gear, driver or driven machine.

TAD Thrust collar technologyThe thrust-collar gear unit with single-helical toothing, compensated axial tooth pressures and a guide bearing on the low-speed shaft to reduce the power loss.

Our Experience Helps to Findthe Optimum Shaft ArrangementThe Genuine RENK TA Gears Famous for Reliability

Quill shaft

Coupling(axial fire float)

Turbine / Compressor

Ridigid coupling

Generator / motor

Ridigid coupling

Generator / motor

Coupling(axial lock)

Quillshaft in bullgearDIN 5480

9

Gear Units – Technical Features

Criterias for the selection of Plain Bearings

Vacuum Technology for Reduced Losses and More Operational Safety

Irrespective of the type of toothing which is selected (spur, single or double helical) two phenomenons are observed during the operation of high-speed high-power gear units which occur independently.Both have a disturbing effect on the tooth contact pattern which calls for countermeasures.

Power loss by wisidag and bearing

losses can be cut by up to 50 %.

Peak oil temperature can be reduced

by more than 50 °C.

Lifetime of Oil and gearset can

be increased.

10

RENK reporting tool for lateral critical speed calculation has been improoved

since its introduction in 1984 so that automatic reports on realistic shaft and

bearing data are provided – vibration problems are a matter of the past.

The quatation includes a full set of calculations of all gear features. The

quoted gear is next to what is build.

RENK is one of the worlds leading makers of sleeve bearings – a Know How

and Know Why you should participate in.

11

Test stand etax – Gear unit

RENK Aktiengesellschaft

Werk AugsburgGögginger Straße 73 86159 AugsburgGermanyTelefon +49.821.5700-0Telefax +49.821.5700-460E-Mail info.augsburg@renk.biz

www.renk.eu